prepared by – shachi kant jha ©

Understanding Highway Projects Prepared By – Shachi Kant Jha© www.skjhaonline.com

Presentation OnUnderstanding Highway

Projects in India


Contents

Tendering

Planning

Execution

Monitoring

Billing

Costing & Budgeting


TENDERING


Tendering

First of all “Authority / Client” invites tender proposal based on initial survey or feasibility report done by consultants hired by the authority.

Types of Contracts:There are different types of contracts for highway works, out of which any one chosen by the client based on feasibility report. Various types of contracts are as under:

EPC Contract : EPC (Engineering, Procurement & Construction)

contracts are in which the contractor execute the work as per

specifications with own procured materials and claims periodically bills to

the clients for his work done as per item rate BOQ.

After completing the project there is the provision of maintenance period

for which the project should be maintained by the contractor with or

without any cost as described in the agreement.


Tendering

BOT (Toll) / DBFOT Contract : DBFOT (Design, Built, Finance,

Operate and Transfer) contracts are in which the contractor called

concessionaire which may be the SPV (Special Purpose Vehicle) who is

responsible for

• Design the work as per specification & contract normally the

concessionaire engaged design consultant for this purpose.

• Execute the work as per specifications & design normally the

concessionaire choose the EPC contractor for the execution. It may be

his own subsidiary or any other company which execute the work as

per EPC contract.

• Arrange the Finance for the project. Detail financing elaborated

further.

Contd………


Tendering

BOT / DBFOT Contract Contd…..

• Operate & collect the toll for the stipulated concession period (it may

be 10 to 30 years as per contract) and recover his expenses with

interest and after that his profit. Within this period the concessionaire

also responsible for the maintenance of the road.

• After completion of concession period the highway stretch will be

transferred to authority / client.


Tendering

BOT (Annuity)/ DBFOT Contract : All the procedures are same as

described for BOT (Toll) the only difference is that instead of toll collection

the authority disbursed fixed Annual Amount upto the concession period

as per the agreement (2 installments per year).

This type of contract awarded where traffic volume is less & toll collection

is not viable.


Tendering

OPRC Contract : Output and Performance-based Road Contracts is

the new contract type mainly used for the world bank projects. This is

same as EPC contract but the difference is the EPC contract has an

itemized BOQ and its rate and OPRC has lump-sum deliverable item

based rate. Also for this type of project first step is for financial bid and

second is for technical bid which can be qualify by only the contractor who

have given good output and better performance in their previous works.


TenderingExecution cycle for a EPC Contract

Proposal of BidSite Visit &

Cost Estimation

Pre- qualification

Financial BidProject

Awarded

Letter of Acceptance

(LOA)

Signing of Agreement

Execution of Project

Pre-construction

Activities

Project Planning

Work Execution

Periodic Billing

Finishing Works

Project Completion & Handover

Final Bill


TenderingExecution cycle for a BOT(Toll)/DBFOT Contract

Proposal of BidSite Visit &

Cost Estimation

Pre- qualification

Financial BidProject

Awarded

Letter of Acceptance

(LOA)

Signing of Agreement

Traffic Survey & Forecast

Financial Model

Financial Closer

Awarding & Execution of EPC Contract

Project Completion & Commercial Operation

Toll Collection &

Maintenance for entire

Concession Period

Project Handing over to the client


TenderingFinancing the BOT Projects

EPC Cost/ Construction Cost

Non -EPC Cost / Non-Construction Cost(IDC, Financing charges, consultancy

etc.)

Total Project Cost(TPC)

Equity (To be infuse by the

Concessionaire)

Debt (To be taken as loan

from banks)

Grant (To be infuse by the

Client)

Grant is the part of amount which the client is to be infuse in the project but now a days some projects have negative grant or it called premium which amount concessionaire gives to the client / authority from the project.


PLANNING


Planning

Macro Planning

This is an initial work plan at the time of starting of the project to find out the better way for working with major sections and items.

it is a base programme for further planning.

It can be submitted to the Client / Consultants.


Planning

Micro Planning

This is a detail work plan for execution of work which includes all the activities linked with each other with appropriate relations.

What we can do with this:

Finding out the critical tasks.

Plan for utilization of our resources.

Anytime execution detail.

Anytime requirement of Equipments & Materials.

After updating the programme we can know the delay and find out the

better solution to finish the work in time.


EXECUTION OF WORK


WORK EXECUTION

Pre-Construction ActivitiesBefore starting the construction activities, we have to do some pre-construction activities as follows:

Camp / Office Construction.

Survey & Alignment works.

Establishment of Plants and mobilization of Equipments.

Appointment of Key personals & supporting staffs.

Finalization of Design & Drawings (For DBFOT projects).

Land acquisition status and pressurize the authority if acquisition

balance.

Removal of encroachments.

Shifting of utilities apart from ROW.


WORK EXECUTIONConstruction Activities

We have to execute the work as per design & drawings. To quantify & bill the executed work we have BOQ (Bill of Quantity) for every project. Generally the BOQ item heads for Highway projects are as follows:

Item No. 1 – Site Clearance – C & G, Dismantling, tree cutting, stump removal etc. Item No. 2 – Earth Work – Excavation (Soil, rock etc.), Earth Filling (Embankment, Sub-grade, Shoulder, Median etc.) Item No. 3 – Sub-Base – Granular Sub-Base (GSB), Wet Mix Macadam (WMM), Drainage layers etc. Item No. 4 – Bituminous Course – Primer, Tack Coat, BM, DBM, BC etc. Item No. 5 – Structure Works – Cross-Drainage (CD) works, Culverts, Bridge, ROB, Under Pass, Grade-separators etc. Item No. 6 – Drainage & Protection – Road side drains, Pitching, Turffing & other slope protection works. Item No. 7 – Junctions – Junction improvement works. Item No. 8 – Traffic Signage, Marking & Other Appurtenances - Kerb, Km stones, Signage, Road Markings, Guard rails, Crash barriers etc. Item No. 9 – Miscellaneous Works – Photographs, Lightings, Signals, Cars, etc. Item No. 10 – Maintenance Work – Pot – hole repair & Existing road maintenance. Item No. 11 – Toll Plaza – Toll plaza building, Booth & All provisions ( BOT Projects)


WORK EXECUTIONUnderstanding Major Highway Works

OGL & C&G

Embankment

ExcavationSub-Grade

GSB

WMM

BM/DBM

BC

KerbMedianEarthen Shoulder

Primer / Tack Coat


WORK EXECUTION - Understanding Major Highway Works

OGL :For future reference and payment we have to take original ground level (OGL) at defined offsets and existing road edge etc.

Equipments Used :

Auto Level & Staff Total Station



Clearing & Grubbing (C&G)This work shall consist of cutting, removing and disposing of all materials such as trees,bushes, shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150 mm inthickness, rubbish etc.

MORTH Specification Clause - 201

Equipments Used :

Dozer Grader



Excavation (Soil & Rock)The work shall consist of excavation, removal and satisfactory disposal of all materials necessary for the construction of roadway, side drains and waterways in accordance with requirements of Specifications and the lines, grades and cross-sections shown in the drawings or as indicated by the Engineer. MORTH Specification Clause – 301.Equipments Used :

Excavator GraderTipper Water Tanker

Rock Breaker (For rock only)



Earth Filling (Embankment, Sub-Grade, Median, Earthen Shoulder etc.):As per X-section & level required for formation we have to fill earth in lower area and prepare the Embankment after that the Sub-grade of required thickness also to be construct.Filling in median and preparation of earthen shoulder has to be done as shown in X-section.MORTH Specification Clause : 305, Material Used : Earth (Soil) / Moorum.Equipments Used :

Excavator GraderTipper Water Tanker

Vibratory Compactor



Granular Sub-Base (GSB) :This work shall consist of laying and compacting well-graded material on prepared sub-grade in accordance with the requirements Specifications. The material shall be laid in one or more layers as lower sub-base and upper sub-base it also called drainage layer.MORTH Specification Clause : 401, Material Used : Natural / Crushed Aggregate, sand etc.Equipments Used :

Excavator For Mixing GraderWheel Loader

Water Tanker Vibratory Compactor

Tipper



Wet Mix Macadam (WMM):This work shall consist of laying and compacting clean, crushed, graded aggregate and granular material, premixed with water, to a dense mass on a prepared sub-base/base or existing pavement as the case may be in accordance with the requirements in Specifications.MORTH Specification Clause : 406, Material Used : Crushed Aggregate, Stone Dust etc.Plant & Equipments Used :

WMM Plant PaverWheel Loader

Water Tanker Vibratory Compactor

Tipper



Concrete Kerb:Concrete Kerb / Divider is the item which makes median and separate the lane of the road.

MORTH Specification Clause : 408, Material Used : Concrete (Mostly M-20 grade).

Plant & Equipments Used :

Kerb Casting Machine

Concrete Batch Mix Plant

Water Tanker

Transit Mixer



Primer Coat:This work shall consist of the application of a single coat of low viscosity liquid bituminous material to a porous granular surface preparatory to the superimposition of bituminous treatment or mix.MORTH Specification Clause : 502, Material Used : Bitumen emulsion (Slow Setting).

Equipments Used :

Bitumen Distributer / Browser

Mechanical Broomer



Tack Coat:This work shall consist of the application of a single coat of low viscosity liquid bituminous material to an existing bituminous road surface preparatory to the superimposition of a bituminous mix, when specified in the Contract or instructed by the Engineer.MORTH Specification Clause : 503, Material Used : Bitumen emulsion (Rapid Setting).

Equipments Used :

Bitumen Distributer / Browser

Mechanical Broomer



Bituminous Macadam (BM) / Dense Bituminous Macadam (DBM):This is a bituminous mix item to be laid over WMM or existing road on prepared surface. Bituminous Macadam (BM) is a more open graded than the Dense Bituminous Macadam (DBM).The Profile Correcting Course (PCC) also can be done by these items to correct the existing road’s profile.MORTH Specification Clause : 504 & 507, Material Used : Crushed Aggregate, Stone Dust, Bitumen & Filler (lime or cement) if required. Plant & Equipments Used :

Hot Mix Plant PaverWheel Loader

Tandem Roller Pneumatic Roller

Tipper

Water Tanker



Bituminous Concrete(BC):This is a top surface layer of Highway a bituminous mix item to be laid over BM/DBM. It also called wearing course.MORTH Specification Clause : 509, Material Used : Crushed Aggregate, Stone Dust, Bitumen & Filler (lime or cement) if required.Plant & Equipments Used :

Hot Mix Plant PaverWheel Loader

Tandem Roller Pneumatic Roller

Tipper

Water Tanker


WORK EXECUTIONUnderstanding Structure Works

Cross Drainage : These type of structures used to drain out the natural water flow from one side of road to other side so it calls cross drainage structures. Following are the type of cross drainage structures mainly used in highway works :1- Box Culverts2- Slab Culverts3- Pipe Culverts

Bridges : These structures are bigger than the culverts and used to construct on major highway hurdles like Canal, River, Major X-ing, Railway tracks etc. Following are the type of bridges mainly used in highway works :1- Minor Bridge – The bridge span less than 60m of length called minor bridge.2- Major Bridge – The bridge span more that 60m of length called major bridge.3- ROB (Rail Over Bridge) – As stated in the name it construct over a railway line.4- RUB (Rail Under Bridge) – As stated in the name it construct under a railway line.5- Flyover/Over Pass – These type of structures construct over any major junction or crowded area.6- Grade Separator – These type of structures used to construct where major highways cross each other and they need to connected without disturbing traffic movements.7- Underpass – When the main road cross any other road or rail or any hurdle below it called underpass..8- Pedestrian crossing (PX) / Cattle Crossing (CX) – These type of structures used to cross the main road by pedestrian or cattle. Mostly it a box type structure.



BOX CULVERT : As per its name it is monolithic box type structure. It may be single or multiple box type as shown in the picture. It may be precast also.



SLAB CULVERT : These type of culverts has different parts as foundation(Raft), Wall , Bracket & Slab. It may have separate foundation for each wall or combined also as per design requirements.



PIPE CULVERT : These type of culverts made of RCC Hume pipe having dia 300mm to 2000mm. The different parts of these culverts are PCC below pipe, RCC Hume pipe & Head wall etc. As per IS-458 classification concrete pipes are NP(Non-Pressure)-1, NP-2, NP-3 & NP-4 and P(Pressure)-1, P-2, P-3. Normally NP-4 pipe used for pipe culverts in highways.



MINOR BRIDGE : The bridge span less than 60m of length called minor bridge. It can be BOX type Structure or having different structure segments ie. Foundation (Raft or Pile), Substructure (Pier, Pier cap or Wall), Super structure (Diaphragm wall, RCC Girder or Steel Girder, Slab etc.)



MINOR BRIDGE



MAJOR BRIDGE : The bridge span more than 60m of length called minor bridge. It have different structure segments ie. Foundation (Raft or Pile or Well), Substructure (Pier, Pier cap), Super structure (Diaphragm wall, RCC Girder or Steel Girder, Slab etc.)


WORK EXECUTIONUnderstanding Structure Works MAJOR BRIDGE


WORK EXECUTIONUnderstanding Structure Works ROB


WORK EXECUTIONUnderstanding Structure Works RUB


WORK EXECUTIONUnderstanding Structure Works FLYOVER


WORK EXECUTIONUnderstanding Structure Works GRADE SEPARATOR


WORK EXECUTIONUnderstanding Structure Works UNDER PASS



Pedestrian Crossing Cattle Crossing


WORK EXECUTIONProcess Flow of General Major Item Execution in Highway

Boulder Extraction

Stock @ Crusher Plant

Boulder Crushing in Crusher Plant with the help of other

equipments & Labour.

Materials Obtains after crushing of

boulder :40mm Agg.20mm Agg.10mm Agg.Stone Dust

By Tipper

Through Weigh Bridge

Stock @ Crusher Plant

By Tipper & Loader

Stock @ Central Store

By Tipper


Other purchased Item like Cement, Bitumen,

Emulsion etc.

Materials stock @ Production Plant :

Aggregates, Cement/Bitumen &

Other Materials

Materials Issue

Processing in production plants

like WMP/HMP/RMC

plants with Materials & Other

Equipments

Processed Material reached at Site and with

the help of some other Equipments

& Labours it become a final

BOQ Item


By Tipper / TM


MONITORING


Monitoring

Daily Progress ReportThis is a daily basis report of work done at site with all the details showing physical progress, financial progress, equipment and manpower utilization etc. (It will be generated at the site and sent to Corp. for further information & utilization)

What we can do with this: All the functions of PMC are depends on this report. All other reports like weekly progress, monthly progress, status of highway and structures can be made with this. It will helps to update the work programme. It’s summarized report can be send to upper Management for daily progress review.

Monitoring is an essential part of any project. To know the progress of

work and to plan further action daily progress have to be monitored

without fail.


Monitoring

Monthly Progress Report

This is a detail report about monthly status of the project comprising with upto date Physical & Financial progress and overall project status as on date with some graphical charts.


Based on this report we can prepare the MPR for Client / Consultants.

This report will show the overall status so that we can plan our further

step.

It will show us the actual status of hindrances and other problems for

the project.

It will helps to update the work programme.


Monitoring

Updating Highway Strip Chart

Highway is a linear part of the project so the progress can be monitor with the strip chart with all the major layers.


It will show the physical progress of Highway works at a glance.

It will show the Hindrances / Land availability status.

With the help of this chart we can calculate the work done and balance

quantities of highway.

It will help to know the linear progress of all the layers.


Monitoring

Updating Structure Strip / Pictorial Charts

To know about the structure wise progress at a glance this is the best way to maintain the pictorial chart for individual structures.


It will show the physical progress of Structure works at a glance.

With the help of this chart we can calculate the work done and balance

quantities of Structures.

It will help to know the actual status of structures and to finalize the

further step for structure progress.


Monitoring

Other Reports

Some other report which can help for monitoring the projects are as follows :

Daily Manpower Status : It will show the status of manpower present

at site and further requirement if any.

Daily Equipment Status : It will show the status of equipments

deployed at site, working, idling and breakdown status and further

requirement if any.


BILLING


Billing

Monthly Running Account Bill (R.A.Bill)

A periodic RA Bills to has be claimed to the client for payment of work done items. This is very important part of the project because the cash – flow depends on the correct claims made and timely payment released by the Client / Authority. Following checks should be done for billing:

Quantities claimed in the bill is correct.

The method for calculating the quantities is correct.

How much quantities are with held.

Previous with held quantities paid or still with held if yes then reason

for held.


Billing

Monthly Comparison Charts (To be made by site staff)

Following comparison charts should be made on monthly basis:

Actual Work done and Billed quantities.

Quantities billed by us and paid by clients including reason for

deductions (If any).

Quantities billed by Sub-Contractors and paid by us.


Billing

Tracking of Non BOQ Items

The items which don't exist in BOQ called Non-BOQ or Extra Items. For the payment of these item we must have approval of quantities and rates. The checks for these type of items are as follows:

How much quantity is going to be execute?

Is the item similar to any other BOQ item ?

If yes then derive the rate from that particular item.

If no then make a proper rate analysis.

The rate & quantity is to be approved by client.

After approval all executed quantity should be paid.


Billing

Tracking of Variation Items

The items which exist in BOQ but the quantity of that particular item overshoot from BOQ quantity called Variation Item. For the payment of these item we must have approval of quantities only. The checks for these type of items are as follows:

How much quantity is going to be execute further?

The quantity is to be approved by client.

After approval all executed quantity should be paid.


Billing

Re-Conciliation of Major Materials

Upto date and monthly material re-conciliation should be done for the following major materials :

Aggregate & GSB material.

Fine sand & coarse sand.

Bitumen

Cement

Steel ReinforcementRe-Conciliation of Major Materials will be done by comparing the consumption by Job Mix Formula and actual consumption done at site as per store records.


Costing & Budgeting

Costing of Balance Work

To find out the balance cost to go for any particular project , periodical costing will be done on following basis:

Actual balance work quantity.

Actual rate of Materials as on date.

Actual PRW rate as on date.

Actual Sub-contractor’s rate.

Actual Equipment output.


Costing & Budgeting

Budgeting for Balance Work

On the basis of actual cost to go and work programme for any particular

project, monthly head wise budget for the balance work can be prepared.


PHOTOGRAPHS


Photographs

Stone Crusher Plant


Photographs

Dozer at spreading work


Photographs

Shuttering & Bar Binding Work in Progress


Photographs

Concrete Pump Pouring Concrete


Photographs

Gantry Crane for Girder Erection


Photographs

PSC Girder Erected Over Pier Cap


Photographs

Road With Concrete Guard Stone


Photographs

Stone Pitching for Slope Protection


THANKS FOR YOUR KIND ATTENTION

prepared by – shachi kant jha ©

Documents

type of contract

oprc contract

specification contract

bot dbfot contract

bot toll dbfot contract

new contract type

epc contractor

bot annuity dbfot contract